U.S. patent application number 15/450525 was filed with the patent office on 2017-06-22 for methods of making reduced sodium food products formed of potassium-containing emulsifying salt mixtures.
The applicant listed for this patent is Land O'Lakes, Inc.. Invention is credited to Thomas Alexander Glenn, III.
Application Number | 20170172168 15/450525 |
Document ID | / |
Family ID | 50187940 |
Filed Date | 2017-06-22 |
United States Patent
Application |
20170172168 |
Kind Code |
A1 |
Glenn, III; Thomas
Alexander |
June 22, 2017 |
METHODS OF MAKING REDUCED SODIUM FOOD PRODUCTS FORMED OF
POTASSIUM-CONTAINING EMULSIFYING SALT MIXTURES
Abstract
A method of preparing a less sodium food product involves
forming a reaction mixture of one or more of liquid sodium
potassium hydrogen phosphate and liquid sodium dipotassium
phosphate and combining a food ingredient with the emulsifying salt
mixture. A reduced sodium process cheese product is formed of a sol
to gel conversion fat stabilized via a hydrated protein matrix by a
combination of potassium caseinate and sodium caseinate in which
the caseinates are derived from an emulsifying salt mixture of
liquid sodium potassium hydrogen phosphate and liquid sodium
dipotassium phosphate, which, prior to reaction, accounts for at
least about 2.5 and up to about 8.32 percent by weight of a total
weight of the process cheese product. The emulsifying salt mixture
formed of the reaction mixture remains in solution at ambient
conditions for at least two weeks prior to incorporation with a
food ingredient.
Inventors: |
Glenn, III; Thomas Alexander;
(Shoreview, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Land O'Lakes, Inc. |
Arden Hills |
MN |
US |
|
|
Family ID: |
50187940 |
Appl. No.: |
15/450525 |
Filed: |
March 6, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13599751 |
Aug 30, 2012 |
9622496 |
|
|
15450525 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23C 19/082 20130101;
A23C 2250/05 20130101 |
International
Class: |
A23C 19/082 20060101
A23C019/082 |
Claims
1. A method of preparing a dairy product comprising: combining a
dairy ingredient with an emulsifying salt mixture of one or more of
liquid sodium potassium hydrogen phosphate or liquid sodium
dipotassium phosphate to form the dairy product, wherein the liquid
sodium potassium hydrogen phosphate, the liquid sodium dipotassium
phosphate or a combination thereof accounts for at least 50 percent
of the emulsifying salt mixture, and wherein any sodium hydroxide
in the emulsifying salt mixture is less than 0.05 percent by weight
of the emulsifying salt mixture.
2. The method of claim 1, further comprising, prior to the step of
combining, reacting, in solution, one or more of potassium
hydroxide with sodium dihydrogen phosphate or sodium hydroxide with
potassium dihydrogen phosphate to form the emulsifying salt
mixture.
3. The method of claim 2, wherein the potassium hydroxide or the
sodium hydroxide, prior to reacting in the emulsifying salt
mixture, accounts for at least about 0.5 and up to about 4 percent
by weight of the total weight of the dairy product.
4. The method of claim 2, wherein the sodium dihydrogen phosphate
or the potassium dihydrogen phosphate, prior to reacting in the
emulsifying salt mixture, accounts for at least about 2 and up to
about 6.67 percent by weight of the total weight of the dairy
product.
5. The method of claim 1, wherein the emulsifying salt mixture
accounts for at least about 2.5 and up to about 8.32 percent by
weight of a total weight of the dairy product.
6. The method of claim 1, wherein the dairy ingredient comprises
cheese, the method further comprising: heating the combination of
the cheese and the emulsifying mixture to form a process cheese
product.
7. The method of claim 1, wherein the emulsifying salt mixture
exhibits a reduced level of crystallization compared to a disodium
phosphate-based emulsifying salt mixture that is substantially free
of potassium.
8. A method of preparing a dairy product comprising: combining a
dairy ingredient with an emulsifying salt mixture of one or more of
liquid sodium potassium hydrogen phosphate or liquid sodium
dipotassium phosphate to form the dairy product, wherein at least
one of sodium potassium hydrogen phosphate or sodium dipotassium
phosphate accounts for at least 50 percent of the emulsifying salt
mixture, and wherein the emulsifying salt mixture, prior to
reaction, accounts for at least about 2.5 and up to about 8.32
percent by weight of a total weight of the dairy product.
9. The method of claim 8, further comprising, prior to the step of
combining, reacting, in solution, one or more of potassium
hydroxide with sodium dihydrogen phosphate or sodium hydroxide with
potassium dihydrogen phosphate to form the emulsifying salt
mixture.
10. The method of claim 9, wherein the potassium hydroxide or the
sodium hydroxide, prior to reacting in the emulsifying salt
mixture, accounts for at least about 0.5 and up to about 4 percent
by weight of the total weight of the dairy product.
11. The method of claim 9, wherein the sodium dihydrogen phosphate
or the potassium dihydrogen phosphate, prior to reacting in the
emulsifying salt mixture, accounts for at least about 2 and up to
about 6.67 percent by weight of the total weight of the dairy
product.
12. The method of claim 8, wherein the dairy ingredient comprises
cheese, the method further comprising: heating the combination of
the cheese and the emulsifying mixture to form a process cheese
product.
13. A method of forming an emulsifying salt mixture comprising:
reacting, in solution, one or more of potassium hydroxide with
sodium dihydrogen phosphate or sodium hydroxide with potassium
dihydrogen phosphate to form an emulsifying salt mixture of one or
more of liquid sodium potassium hydrogen phosphate or liquid sodium
dipotassium phosphate, wherein the liquid sodium potassium hydrogen
phosphate, the liquid sodium dipotassium phosphate or a combination
thereof accounts for at least 50 percent of the emulsifying salt
mixture, and wherein any sodium hydroxide in the emulsifying salt
mixture is less than 0.05 percent by weight of the emulsifying salt
mixture.
14. The method of claim 13, wherein the potassium hydroxide or the
sodium hydroxide, prior to reacting in the emulsifying salt
mixture, accounts for about 10 to about 55 percent of the
emulsifying salt mixture.
15. The method of claim 13, wherein the sodium dihydrogen phosphate
or the potassium dihydrogen phosphate, prior to reacting in the
emulsifying salt mixture, accounts for about 20 to about 55 percent
of the emulsifying salt mixture.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation of U.S. Ser. No.
13/599,751 filed Aug. 30, 2012, the contents of which are hereby
incorporated by reference.
FIELD OF TECHNOLOGY
[0002] Implementations are directed to food products, and more
particularly are directed to less sodium food products and methods
of making and using such products through the use of
potassium-containing liquid emulsifying agents.
BACKGROUND
[0003] Process cheeses are blends of natural cheese, emulsifying
salts and other ingredients. The blends are generally processed
into a molten sol by heating and blending. During processing, the
molten sol may destabilize causing the fat to separate. Emulsifying
salts such as sodium phosphate help prevent fat separation and
control the pH of cheese.
[0004] Fat separation is prevented, or the fat is re-incorporated
in the homogenous mixture during the heating and cooking process
using the emulsifying salts. The emulsifying salts participate in
an ion exchange reaction with caseins, the main protein source in
natural cheese. The ion exchange process involves the removal of
calcium from the insoluble collodial calcium phosphate complexes
that stabilize casein-casein interactions in the gel matrix of the
cheese. In effect, the divalent cation calcium is replaced by the
monovalent cation sodium within the casein matrix through this
process, solubilizing the colloidal calcium phosphate complex,
converting calcium caseinate to sodium caseinate. Once the calcium
is separated from the casein, the more hydrophobic regions of the
casein can more effectively interact with the milk fat and the more
hydrophilic regions of the casein can more effectively interact
with the water transitioning from a gel state to a sol state. Thus,
when the casein is separated from calcium, it acts as an emulsifier
to stabilize the sol, thus allowing the components to combine. Upon
cooling the transition from the sol state to a gel state is
complete wherein the hydrated protein matrix stabilizes the fat in
the product.
[0005] Emulsifying salts also control the pH of the cheese, which
facilitates the organoleptic properties of the cheese by keeping
the cheese from being too acidic or basic.
[0006] These salts also contribute to providing a smooth, creamy
texture of the finished product and enable slices and spreads with
varying firmness and melting properties to be produced. For
example, process cheese may be poured into molds or shaped into
slices and may resist melting, while some process cheese spreads
melt readily to provide a pourable product.
[0007] Although emulsifying salts are required for the production
of process cheese, their addition results in process cheese
products having a relatively high sodium concentration compared to
their natural cheese counterparts.
SUMMARY
[0008] Emulsifying salt mixtures with potassium-containing liquid
emulsifying agents, and systems and methods of making reduced
sodium food products using the emulsifying agents are provided
herein.
[0009] According to some implementations, a method of preparing a
less sodium food product involves forming a reaction mixture of one
or more of liquid sodium potassium hydrogen phosphate and liquid
sodium dipotassium phosphate, and combining a food ingredient with
the emulsifying salt mixture to form the less sodium food product.
In some implementations, the food product may be process
cheese.
[0010] In other implementations, a reduced sodium process cheese
product, upon cooling, includes a sol to gel conversion fat
stabilized via a hydrated protein matrix by a combination of
potassium caseinate and sodium caseinate. The potassium and sodium
caseinate are derived from an emulsifying salt mixture of one or
more of liquid sodium potassium hydrogen phosphate and liquid
sodium dipotassium phosphate, and the emulsifying salt mixture,
prior to forming the product, accounting for at least about 2.5 and
up to about 8.32 percent by weight of a total weight of the process
cheese product.
[0011] In further implementations, an emulsifying salt mixture
includes a reaction mixture of one or more of liquid sodium
dihydrogen phosphate in reaction with liquid potassium hydroxide
and liquid potassium dihydrogen phosphate in reaction with liquid
sodium hydroxide to form one or more of liquid sodium potassium
hydrogen phosphate and liquid sodium dipotassium phosphate. The
emulsifying salt mixture remains in solution at ambient conditions
for at least two weeks prior to incorporation in a food
ingredient.
[0012] In further implementations, an emulsifying salt mixture
includes a reaction mixture of one or more of liquid sodium
dihydrogen phosphate in reaction with liquid potassium hydroxide
and liquid potassium dihydrogen phosphate in reaction with liquid
sodium hydroxide to form one or more of liquid sodium potassium
hydrogen phosphate and liquid sodium dipotassium phosphate. This
emulsifying salt mixture may also include residual unreacted liquid
sodium dihydrogen phosphate or unreacted liquid potassium
dihydrogen phosphate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a method of producing a process cheese
product having a reduced sodium content according to certain
implementations.
[0014] FIG. 2 illustrates a multivariate analysis of the Example in
which control, liquid dipotassium phosphate and liquid potassium
hydroxide samples were analyzed using a principal component
analysis (PCA) bi-plot of significantly different quantitative
descriptive analysis (QDA) attributes.
DETAILED DESCRIPTION
[0015] Implementations of the present disclosure are directed to
emulsifying salt mixtures with potassium-containing liquid
emulsifying agents, and systems and methods of making reduced
sodium food products, including reduced sodium process cheese
products, using the emulsifying agents.
[0016] In prior approaches, sodium phosphate emulsifying salts have
been used as a major source of sodium in food products such as
dairy-based products including process cheese. The sodium present
in these emulsifying salts contributes to the total sodium of the
food product, thereby making it difficult to produce food products
with a low or reduced sodium content. One approach has been to
reduce the level of sodium phosphate by replacing a portion of
disodium hydrogen phosphate (e.g., Na.sub.2HPO.sub.4) with
dipotassium hydrogen phosphate (e.g., K.sub.2HPO.sub.4). Although a
partial replacement of disodium hydrogen phosphate
(Na.sub.2HPO.sub.4) with dipotassium hydrogen phosphate
(K.sub.2HPO.sub.4) can achieve similar product attributes in, for
example, reduced sodium cheeses, such processes require the
management of incorporating two separate phosphate emulsifying
salts.
[0017] Less Sodium Potassium-Containing Emulsifying Salt
Mixtures.
[0018] Implementations herein provide advantages over prior
approaches that use sodium phosphate-based emulsifying salts (e.g.,
sodium dihydrogen, disodium hydrogen and trisodium phosphate
emulsifying salts) and over the use of separate additions of sodium
and potassium phosphates by providing a liquid sodium potassium
phosphate-based emulsifying salt mixture (e.g., NaKHPO.sub.4) for
use in the production of food products including dairy-based
products such as process cheese. It has been discovered that food
products produced using sodium potassium hydrogen phosphate have
improved organoleptic properties compared to food products produced
using emulsifying salt mixtures of a reaction of sodium dihydrogen
phosphate and sodium hydroxide along with dry or liquid forms of
dipotassium hydrogen phosphate. Further, it has been discovered
that process cheese products provided according to implementations
herein exhibit substantially no crystallization on the surface of
sliced cheese products after several days compared to process
cheese produced using the above-described sodium phosphate-based
emulsifying salts.
[0019] According to certain implementations, a liquid emulsifying
salt mixture may be provided by reacting liquid sodium dihydrogen
phosphate (NaH.sub.2PO.sub.4(liq)) with liquid potassium hydroxide
(KOH(liq)) to form the liquid sodium potassium hydrogen phosphate
(NaKHPO.sub.4(liq)) emulsifying salt mixture. In addition or
alternatively, the liquid sodium potassium hydrogen phosphate
(NaKHPO.sub.4(liq)) emulsifying salt mixture may be formed by
reacting liquid potassium hydrogen phosphate
(KH.sub.2PO.sub.4(liq)) with liquid sodium hydroxide
(NaOH(liq)).
[0020] The liquid sodium dihydrogen phosphate or the liquid
potassium hydrogen phosphate in the reaction mixture may be formed
of between about 20 and about 55 percent, or preferably about 45
percent in solution, and, prior to reaction, may account for
between about 2 to about 6.67 percent by weight, and preferably
about 3.5 percent by weight, of the total weight of the composition
of the food product. Liquid potassium hydroxide or the liquid
sodium hydroxide may be formed of about 10 to about 55 percent, or
preferably about 50 percent in solution, and, prior to reaction,
may account for between about 0.50 and about 4 percent, and
preferably about 1.2 percent, by weight of the total weight of the
composition of the food product.
[0021] In the emulsifying salt mixture, as the amount of potassium
hydroxide increases, hydrogen may be displaced in the sodium
potassium hydrogen phosphate with potassium to form sodium
dipotassium phosphate (NaK.sub.2PO.sub.4(liq)). In particular, the
potassium cations in the reaction mixture readily interact with the
weak sodium phosphate acid (e.g., sodium dihydrogen phosphate
NaH.sub.2PO.sub.4) forming a sodium potassium phosphate complex.
This is accomplished via a dynamic equilibrium process wherein the
reaction begins between the hydroxide component of the potassium
hydroxide base as it solubilizes into solution and free hydrogen in
the environment forming water in the reaction. This consequently
shifts the ratio of free hydrogen and free hydroxide in the system
and in an attempt to maintain the noted equilibrium quantities of
free hydrogen and free hydroxide, hydrogen shifts off of the sodium
dihydrogen phosphate and into solution, thus promoting the sodium
potassium phosphate complex to form. With increased potassium
hydroxide, more hydrogen is ultimately displaced in an effort to
maintain the noted equilibrium in the environment. Similarly, as
the amount of sodium hydroxide increases, hydrogen may be displaced
in the sodium potassium hydrogen phosphate with sodium to form
disodium potassium phosphate (Na.sub.2KPO.sub.4 (liq)).
Accordingly, with increased sodium hydroxide, more hydrogen may be
displaced.
[0022] Therefore, in some implementations, an emulsifying salt
mixture includes a reaction mixture of one or both of liquid sodium
dihydrogen phosphate (NaH.sub.2PO.sub.4) in reaction with liquid
potassium hydroxide, and liquid potassium dihydrogen phosphate
(KH.sub.2PO.sub.4) in reaction with liquid sodium hydroxide, to
form one or more of liquid sodium potassium hydrogen phosphate and
liquid sodium dipotassium phosphate. This emulsifying salt mixture
may also include residual unreacted liquid sodium dihydrogen
phosphate or unreacted liquid potassium dihydrogen phosphate. For
example, the unreacted sodium dihydrogen phosphate or potassium
dihydrogen phosphate may account for up to about 50 percent of the
salt in the emulsifying salt mixture, whereas the sodium potassium
hydrogen phosphate (NaKHPO.sub.4) and/or sodium dipotassium
phosphate (NaK.sub.2PO.sub.4) accounts for at least 50 percent of
the salt and up to 100 percent of the emulsifying salt mixture. The
emulsifying salt mixture may have a pH of between about 6 and 9, or
about 8. However, the pH may vary depending on the desired flavor,
texture and melting attributes of the food product in which the
emulsifying salt mixture is used.
[0023] Where the emulsifying salt mixture is formed of a mixture of
sodium potassium hydrogen phosphate (NaKHPO.sub.4) and sodium
dipotassium phosphate (NaK.sub.2PO.sub.4), the sodium dipotassium
phosphate (NaK.sub.2PO.sub.4) may account for up to about 80
percent of the salt in the emulsifying salt mixture, whereas the
sodium potassium hydrogen phosphate (NaKHPO.sub.4) may account for
at least 20 percent of the salt and up to 100 percent of the
emulsifying salt mixture. The emulsifying salt mixture may have a
pH of between about 9 and 12, or about 9. However, the pH may vary
depending on the desired flavor, texture and melting attributes of
the food product in which the emulsifying salt mixture is used.
[0024] In further implementations, the emulsifying salt mixture may
be formed of a reaction mixture of liquid potassium dihydrogen
phosphate (KH.sub.2PO.sub.4(liq)) with potassium hydroxide
(KOH(liq)) to form dipotassium hydrogen phosphate
(K.sub.2HPO.sub.4(liq)). In yet further implementations, the
aforementioned reaction mixture may additionally include a portion
of liquid monosodium phosphate so that the emulsifying salt mixture
includes a combination of the dipotassium hydrogen phosphate and
sodium potassium phosphate.
[0025] Generally, a composition of the food product includes the
emulsifying salt mixture, prior to reaction, of between about 2.5
and about 8.32 percent by weight, or preferably about 4.7 percent
by weight, of the total weight of the composition of the food
product.
[0026] In some implementations, a small amount of liquid sodium
hydroxide (NaOH) may be included in the reaction mixture with the
KOH(liq) and the NaKHPO.sub.4(liq), such as about 0.1 percent NaOH
of the total weight of the food composition prior to reaction. In
this example, a small fraction of the emulsifying salt mixture may
be composed of disodium hydrogen phosphate
(Na.sub.2HPO.sub.4(liq)), with the predominant form being sodium
potassium hydrogen phosphate (NaKPO.sub.4(liq)). However, it will
be appreciated that the amount of potassium hydroxide is present in
the emulsifying salt reaction mixture by at least a factor of 5
(e.g., at least 0.5 percent of the total weight of the composition)
and in this example, the sodium potassium hydrogen phosphate
(NaKHPO.sub.4) will continue to account for at least 95 percent of
the salt and up to 100 percent of the emulsifying salt mixture as
provided above. Alternatively, the reaction mixture may be
substantially free of sodium hydroxide (e.g., less than 0.05
percent of the weight of the batch).
[0027] In some implementations, the emulsifying salt mixture
exhibits a reduced level of crystallization compared to a sodium
phosphate-based emulsifying salt mixture that is substantially free
of potassium. For example, a reacted mixture yielding disodium
hydrogen phosphate may exhibit crystallization within about two
days when in solution at ambient temperatures, which is in
comparison to the potassium-containing emulsifying salt mixtures of
the present disclosure that exhibit substantially no
crystallization when held at ambient temperatures. For example,
even after about two weeks, potassium-containing emulsifying salt
mixtures held at ambient temperatures exhibit substantially no
crystallization. By remaining in solution at ambient temperatures,
the emulsifying salt mixture may be stored for prolonged periods of
time prior to use, which may be beneficial for storage, shipping
and handling of the emulsifying salt mixture, in contrast to
reacted mixtures yielding disodium hydrogen phosphate, requiring
handling and storage temperatures ranging from 140-200.degree. F.
to prevent crystallization of the mixture prior to use. For
example, after storing at ambient conditions for about two weeks,
the emulsifying salt mixture in solution may be used immediately in
a food processing plant as a food product ingredient without
additional processing steps.
[0028] Providing liquid emulsifying salt mixtures of sodium
potassium phosphate, according to the present disclosure,
surprisingly resulted in food products having improved organoleptic
properties. Historically, food products such as process cheese were
taught to have a metallic flavor when prepared with
potassium-containing emulsifying salts. In U.S. Pat. No. 5,466,477,
the reference teaches potassium salts when used in connection with
providing an emulsifying salt, tend to give the negative
organoleptic property of a metallic taste to the dairy product and
consequently teaches the use of sodium hydroxide in forming an
emulsifying salt.
[0029] In contrast, and as provided herein, it has been discovered
that by combining the liquid potassium hydroxide with the sodium
dihydrogen phosphate, the resulting liquid sodium potassium
phosphate emulsifying salt mixtures provide a less sodium food
product having desirable properties (e.g., improved flavor). It is
believed that the combination of sodium and potassium in the sodium
potassium phosphate salts results in a more homogeneously dispersed
environment of sodium and potassium providing a salty flavor to
taste receptors from sodium, which shields taste receptors from an
excess amount of potassium in the food product that may otherwise
impart a metallic flavor. Further, it is believed that with the
liquid state of the reacted components, potassium is more readily
able to displace calcium within the casein protein, thus
interacting with the protein more so than with using a dry
potassium source, reducing the level of free potassium in the
environment that would be more readily available to impart a
metallic flavor. Moreover, the combination of the potassium and
sodium in the liquid solution allows the levels of potassium and
sodium to be controlled in the liquid emulsifying salt mixture,
which is in contrast to dry forms of potassium and sodium
containing emulsifying salts.
[0030] Food Products Including the Emulsifying Salt Mixture.
[0031] A variety of food products may be prepared using the liquid
emulsifying salt mixtures disclosed herein. For example, process
cheese; cheese dips and sauces; cheese powders; imitation cheese;
canned milk; UHT milk; instant pudding; ice cream; frozen desserts;
cooked cereals; extruded dry cereals; and pasta products among
others.
[0032] One type of food product that preferably includes the liquid
emulsifying salt mixture is process cheese. Examples of process
cheese products include, but are not limited to, process cheese
loafs, slices, spreads, sauces, sticks, snacks, and powders.
Cheeses that may be used in the process cheese include, but are not
limited to, Cheddar (e.g., new, old, semi-mature), Mozzarella,
Colby, Swiss, washed curd, enzyme modified and granular cheese.
Other dairy ingredients that may be used in the process cheese
include, but are not limited to, anhydrous milkfat, cream,
dehydrated cream, nonfat dry milk, casein, whey, whey protein
concentrate and milk protein concentrate.
[0033] Nondairy ingredients may include, but are not limited to,
water, vinegar, lactic acid, citric acid, acetic acid, and
phosphoric acid, salt, colorants, spices, preservatives,
flavorants.
[0034] It has been discovered that process cheese products prepared
using the above-described liquid emulsifying salt mixtures, when
sliced and placed on display (e.g., in a deli or in a package)
exhibit lower salt crystallization on the cheese surface compared
to sliced process cheese products prepared using an emulsifying
salt mixture derived from liquid sodium dihydrogen phosphate
reacted with sodium hydroxide to yield liquid disodium hydrogen
phosphate. This is because of disodium phosphate's low solubility
in the water phase of the process cheese. When the process cheese
is sliced and packaged, the headspace of the package can saturate
with moisture vapor and microscopically condense on cheese
surfaces, especially if temperature abused. This promotes a
concentration gradient of dissolved solutes between the bulk water
phase of the process cheese and condensed surface moisture that
creates a driving force for phosphate and other soluble salts to
enter this substantially solute free surface moisture environment.
With limited diffusional resistance within the surface moisture the
disodium hydrogen phosphate can nucleate and crystallize on the
surface depending on pH and other factors, particularly if the
product within the package is temperature abused (i.e., removed
from a refrigerated environment and placed in ambient temperature
for an extended period of time) and the headspace becomes saturated
again with moisture from the condensed surfaces further
concentrating the noted solutes on the slice surfaces promoting the
crystallization phenomenon. In contrast, the sodium potassium
hydrogen phosphate emulsifying salt mixture is a more inherently
stable salt mixture of higher water solubility that yields a
relatively lower amount of crystallization or no crystallization
results on the surface of the sliced cheese. This may improve
handling characteristics and quality of the process cheese
products.
[0035] Method of Forming Process Cheese Using the Emulsifying Salt
Mixture.
[0036] According to certain implementations, a method of producing
a process cheese product having a reduced sodium content may be
produced according to the method 100 of FIG. 1. Although FIG. 1
illustrates a method for producing process cheese, it will be
understood that other dairy-based products may be prepared in the
same or in a similar manner of method 100. In addition, the
dairy-based products that include the liquid emulsifying salt
mixture may be formed in a continuous or batch process.
[0037] The method 100 includes grinding 110 natural cheese or a
blend of natural cheeses to form cheese particulates. The ground
cheese mixture may be transferred to a blender (e.g., a twin ribbon
blender), and other dairy ingredients such as anhydrous milkfat,
dairy powders, water, milkfat, cream, and optionally other
non-diary ingredients such as colorants and flavorants may also be
added 120 to the blender. In some instances, the non-cheese
ingredients may be melted prior to adding 120 to the blender. For
example, anhydrous milkfat may be heated to about 120.degree. F. so
that the melted anhydrous milkfat is combined with the cheese and
other ingredients.
[0038] The mixture may be blended 130 to form a homogenous mixture.
For example, the mixture may be blended for about 5 minutes, but
blending times may vary based on factors such as the weight of the
mixture and speed and holding capacity of the blender. In some
implementations, the blended 130 ingredients may be allowed to sit
prior to further processing, such as for about 1 hour.
[0039] In a separate vessel, a reaction mixture of liquid potassium
hydroxide and liquid sodium dihydrogen phosphate may be allowed to
react 140 to form the liquid sodium potassium phosphate emulsifying
salt mixture, described above. In some implementations, the liquid
potassium hydroxide may be held in a vessel separate from a vessel
holding the liquid sodium dihydrogen phosphate, and the two may be
combined in a third vessel, e.g., a reaction vessel, where the
emulsifying salt reaction takes place. Alternatively, the vessel
holding the liquid potassium hydroxide or the liquid sodium
dihydrogen phosphate may serve as the reaction vessel. As discussed
above, the emulsifying salt mixture may additionally include liquid
sodium dihydrogen phosphate, sodium potassium hydrogen phosphate,
sodium dipotassium phosphate, disodium potassium phosphate,
disodium hydrogen phosphate, dipotassium hydrogen phosphate,
trisodium phosphate, tripotassium phosphate alone or in
combination. Further, the emulsifying salt mixture may include
unreacted sodium dihydrogen phosphate or unreacted potassium
dihydrogen phosphate.
[0040] The liquid emulsifying salt mixture may be transferred from
the reaction vessel and added to a cooker (e.g., a twin ribbon
cooker) along with the cheese mixture from the blender for cooking
150. In some implementations, the liquid emulsifying salt mixture
may be added to the cooker after a portion of the cheese mixture is
added to the cooker (e.g., after approximately 30 percent of the
total amount of the cheese mixture to be provided to the cooker is
added). In some implementations, the first portion of the cheese
mixture may be heated to about 120.degree. F. in the cooker prior
to the liquid emulsifying salt mixture addition. In further
implementations, the addition of the liquid emulsifying salt
mixture may coincide with a steam injection process used to heat
the contents of the cooker. The remaining amount of the cheese
mixture may be added to the cooker and the process cheese
composition may be heated for pasteurization and to produce a sol
of the aqueous and fat components. During the blend or gel to sol
transition, calcium in casein within the cheese mixture may be
displaced by the potassium and sodium to form sodium and potassium
caseinate, which increases the capacity of casein to facilitate the
interaction between the fat and aqueous components in the molten
cheese blend thus stabilizing the mixture. The resulting product
may form a gel during the sol to gel transition upon cooling,
forming a process cheese composition, wherein fat is emulsified in
a hydrated protein matrix. The temperature to which the liquid
emulsifying salt and cheese mixture are heated and heating times
may vary, but in some implementations, the mixture may be subjected
to cooking 160.degree. F. up to about 185.degree. F. for about 1
minute.
[0041] In addition or alternatively, the emulsifying salt mixture
may be added to the blender during blending 130 of the cheese
mixture. For example, all or a portion of the emulsifying salt
mixture may be added to the cheese mixture within the blenders and
may be blended 130 with the cheese, dairy powders, water and
milkfats prior to cooking 150. In this example, the emulsifying
salts may begin reacting with the casein.
[0042] The addition of the emulsifying salt mixture to the
ingredient composition shortly after the reaction of the potassium
hydroxide with the sodium dihydrogen phosphate takes place may add
heat to the blending 130 and/or the cooking 150 processes due to
the exothermic reaction of the emulsifying salt mixture, which
causes the mixture to reach temperatures of about 175.degree. F.
For example, when added during blending 130 shortly after reacting
(e.g., within about 2 minutes), this adds heat to the mixture. In
addition, providing a liquid emulsifying salt mixture facilitates
emulsification of the cheese mixture during blending 130 because
the salts are in solubilized form within the liquid mixture,
whereas the dry forms of emulsifying salts take time to dissolve
and may not completely solubilize, at the temperatures
characteristically used during the blending 130 process. Further,
the liquid emulsifying salt mixture is pumpable and adds handling
flexibility in blending 130 and cooking 150. For example, the
pumpable mixture may be automatically added during batch or
continuous processing of the food composition, whereas dry
emulsifying salts are generally hand added, which increases the
chance of over or under application.
[0043] The process cheese composition containing the noted molten
sol may be packaged 160 using conventional packaging systems, for
example, into loafs or tubs. The process cheese composition may
then be cooled 170 using conventional cooling apparatuses in so
that the packaged product retains its shape, e.g., from molding.
Alternatively, the composition may be further processed into
various forms such as powders, by for example, spray drying. As
another alternative, the composition may be cooled in sheets on
cooling belts in continuous processes and formed into stacks of
ribbons for harping into various slice on slice product
configurations.
[0044] The reduced sodium process cheese products produced
according to method 100 may include a portion of potassium citrate
and sodium citrate as emulsifying agents that serve to stabilize
the fat in the process cheese due to the displacement of calcium in
the casein in conjunction with the sodium and potassium from the
sodium potassium phosphate emulsifying salt. This is in contrast to
process cheese products containing only sodium phosphate-derived
sodium caseinates that are formed by the reaction of the calcium
with the sodium in sodium phosphate (e.g., sodium dihydrogen,
disodium hydrogen and trisodium phosphate).
[0045] Certain aspects provided herein are more particularly
described in the following Example, which is intended for
illustration only, as numerous modifications and variations within
the scope of the present disclosure will be apparent to those
skilled in the art.
Example: Comparison of Less Sodium Emulsifying Salt Compositions in
Process Cheese
[0046] Materials and Methods:
[0047] Three less sodium process cheese formulations were studied
to determine what impact a reaction of sodium dihydrogen phosphate
(MSP (NaH.sub.2PO.sub.4)) with potassium hydroxide (KOH) has on
processing and finished product characteristics in comparison to
dipotassium phosphate combined with sodium phosphate emulsifying
salt mixture. It is believed that reaction of MSP and KOH would
simplify production of reduced sodium process cheese and there
would be no need for a separate dipotassium hydrogen phosphate
(K.sub.2HPO.sub.4) stream to incorporate into the process.
[0048] The three formulations produced used: a control (e.g., dry
dipotassium hydrogen phosphate ("DKP")); a liquid DKP (50% liquid
dipotassium hydrogen phosphate); and a liquid KOH (liquid potassium
hydroxide reacted with sodium dihydrogen phosphate ("MSP") to
produce liquid sodium potassium hydrogen phosphate, so that the
liquid phosphate system carries the entire phosphate load).
[0049] Table 1 below provides the emulsifying salt components used
in the process cheese compositions tested.
TABLE-US-00001 TABLE 1 Sample Emulsifying Salt Components Control
MSP (45% liq), NaOH (50% liq) and hand add Dipotassium Hydrogen
Phosphate (dry) Liquid MSP (45% liq), NaOH (50% liq) and
Dipotassium DKP Hydrogen Phosphate (liquid) Liquid MSP (45% liq),
KOH (50% liq) KOH
[0050] The sodium hydroxide ("NaOH") and MSP emulsifier components
in the control sample were allowed to react prior to addition to
the cooker, while the dry potassium hydrogen phosphate was added by
hand to the cooker. The liquid DKP was formulated with the same
total solids delivery as that delivered in dry dipotassium hydrogen
phosphate formula control. In the liquid DKP sample, each of the
liquid MSP, NaOH were subjected to a reaction and the liquid
dipotassium hydrogen phosphate was added as a separate ingredient
to the cooker. In the liquid KOH sample, the liquid MSP was reacted
with the liquid KOH control to form liquid sodium potassium
hydrogen phosphate (NaKHPO.sub.4) prior to addition to the
cooker.
[0051] Each of the process cheese samples tested included
compositions with cheddar cheese, anhydrous milkfat, dairy powder,
water and sodium chloride. Other than the emulsifier compositions,
the three process cheese compositions tested were substantially the
same.
[0052] For sensory testing, 5 lb. loaf samples were sliced on a
Hobart Slicer (model 2912) to produce a 19 g slice. Slices were cut
in half on a cheese board, stacked, wrapped in plastic wrap, and
transferred to the Delfield cooler. Samples were transferred from
the plastic wrapped stacks to 6'' white paper plates as needed. The
samples were served at a temperature of about 48-52.degree. F.
under white lighting.
[0053] Results:
[0054] Tables 2-4 below provide acceptance ratings from 66
subjects.
TABLE-US-00002 TABLE 2 Formula Overall Dry DKP 6.3 B Liquid 6.2 B
DKP Liquid 6.5 A KOH
TABLE-US-00003 TABLE 3 Formula Flavor Dry DKP 6.2 B Liquid 6.2 B
DKP Liquid 6.6 A KOH
TABLE-US-00004 TABLE 4 Formula Texture/Mouthfeel Dry DKP 6.6 A
Liquid 6.5 A DKP Liquid 6.6 A KOH
[0055] Where for Tables 2-4: 9=Like Extremely; 5=Neither Like nor
Dislike; 1=Dislike Extremely. LS Means followed by different
letters show statistical difference at 95% CI (Duncan's). The
majority of appearance comments of Table 4 involved the number or
size of air holes in the samples.
[0056] Tables 5-18 below provide descriptive analysis ratings from
14 trained panelists.
TABLE-US-00005 TABLE 5 Sticky Formula Mouthfeel.sup.b - Dry DKP
13.1 B Liquid 13.2 B DKP Liquid 14.5 A KOH .sup.bTaking a 2-layer
bite and chewing a little to evaluate degree to which sample feels
sticky, adhesive, clings to teeth, roof of mouth. (slight-very)
TABLE-US-00006 TABLE 6 Formula Cheese Aroma.sup.c Dry DKP 10.5 A B
Liquid 10.6 A DKP Liquid 9.8 B KOH .sup.cPick up the cheese, break
it open, smell the cut edge and evaluate the intensity of cheese
aroma including cheddar cheese aroma. (weak-strong)
TABLE-US-00007 TABLE 7 Graininess Formula Mouthfeel.sup.d - Dry DKP
6.1 A Liquid 6.3 A DKP Liquid 4.8 B KOH .sup.dTaking a 2-layer bite
and chewing a little to evaluate degree to which sample feels
grainy/coarse/not smooth in your mouth. (smooth-grainy)
TABLE-US-00008 TABLE 8 Formula Whey Aroma.sup.e - Dry DKP 8.0 A B
Liquid 8.4 A DKP Liquid 7.7 B KOH .sup.ePick up the cheese, break
it open, smell the cut edge and evaluate the intensity of whey
aroma. (weak-strong) Not Barny whey.
TABLE-US-00009 TABLE 9 Moist Formula Mouthfeel.sup.f - Dry DKP 19.6
B Liquid 19.0 B DKP Liquid 21.2 A KOH .sup.fDuring chewing, degree
to which sample feels oily or moist, not dry. (slight-very)
TABLE-US-00010 TABLE 10 Creamy Formula Mouthfeel.sup.h - Dry DKP
18.7 B Liquid 18.0 B DKP Liquid 21.3 A KOH .sup.hDuring chewing for
approximately 5 to 10 seconds degree to which sample has a creamy
mouthfeel, a full-fat feel. (slight-very)
TABLE-US-00011 TABLE 11 Formula Salty Flavor.sup.i + Dry DKP 14.1 B
Liquid 14.2 B DKP Liquid 15.1 A KOH .sup.iIntensity of salty taste.
(weak-strong)
TABLE-US-00012 TABLE 12 Breakdown Formula Mouthfeel.sup.j - Dry DKP
17.8 B Liquid 17.5 B DKP Liquid 19.0 A KOH .sup.jDuring chewing for
approximately 5 to 10 seconds, the degree to which samples breaks
down in your mouth from lumpy chunks to little pieces to breaks
down completely. (low-high)
TABLE-US-00013 TABLE 13 Full Fat Formula Flavor.sup.k Dry DKP 11.9
A B Liquid 11.5 B DKP Liquid 12.5 A KOH .sup.kIntensity of full-fat
flavor like that found in cream or coconut cream. (weak-strong)
TABLE-US-00014 TABLE 14 Salty Aftertaste/ Formula Afterfeel.sup.l +
Dry DKP 12.7 B Liquid 13.1 B DKP Liquid 13.7 A KOH .sup.lWait 5
seconds after swallowing and mouth is empty to evaluate the
intensity of lingering salty taste remaining. (weak-strong)
TABLE-US-00015 TABLE 15 Buttery Formula Flavor.sup.m + Dry DKP 8.8
B Liquid 8.7 B DKP Liquid 9.4 A KOH .sup.mIntensity of buttery
flavor like butter. (weak-strong)
TABLE-US-00016 TABLE 16 Cheese Aftertaste/ Formula Afterfeel.sup.n
+ Dry DKP 12.7 B Liquid 12.6 B DKP Liquid 13.3 A KOH
.sup.nIntensity of lingering cheese flavor remaining.
(weak-strong)
TABLE-US-00017 TABLE 17 Dairy Sweet Formula Flavor.sup.o + Dry DKP
10.6 A B Liquid 9.9 B DKP Liquid 11.2 A KOH .sup.oIntensity of
dairy sweet flavor like the sweet flavor found in dairy products
(milk, cream, cheese). (weak-strong)
TABLE-US-00018 TABLE 18 Whey Aftertaste/ Formula Afterfeel.sup.p -
Dry DKP 10.1 A B Liquid 10.6 A DKP Liquid 9.8 B KOH .sup.pWait 5
seconds after swallowing and mouth is empty to evaluate the
intensity of sweet whey flavor remaining. (weak-strong) Not Barny
Whey.
[0057] In tables 5-18, the numerical rankings were from low to
high, slight to very and weak to strong, in which a low number
represents the first descriptor and a higher number represents the
second descriptor based on a 60 point scale. LS Means followed by
different letters show statistical difference at 95% CI (Duncan's).
In these tables, a "+" sign indicates positive driver of liking,
and a "-" sign indicates negative driver of liking based on the
more critical consumer segment from the 2007 White Deli American
Drivers of Liking (#3980).
[0058] Results Summary:
[0059] Results from the 66 testers, as shown in tables 2-4, show
significant differences between products in all measures of liking
and significant differences were seen between formulas in overall,
flavor, and appearance liking. The liquid KOH formula prepared
using an emulsifying salt mixture of sodium potassium hydrogen
phosphate was the best-liked formula (overall and flavor).
[0060] From the trained panelists, the formulas affected multiple
significant sensory attributes as reflected in Tables 5-18 above.
The liquid KOH formula had a significantly creamier mouthfeel
compared to the control and the liquid DKP samples (Table 10), and
was moderately moister in mouthfeel compared to the control and the
liquid DKP (Table 9). Small sensory differences were observed in
the cheese and whey aroma; the salty, full fat, buttery and dairy
sweet flavors; the sticky, grainy and breakdown mouthfeel; and the
salty, cheese and whey aftertaste.
[0061] Compared to the control, the liquid KOH samples had
increased positive drivers of liking including buttery and salty
flavor and salty and cheese aftertaste. In contrast, compared to
the control, the liquid DKP had no statistically significant
differences in any of the positive drivers of liking. Compared to
the control, the liquid KOH samples had a decrease in negative
drivers of liking in graininess (Table 7) and approximately the
same whey aroma and whey aftertaste. In contrast, compared to the
control, the liquid DKP had no statistically significant
differences in the negative drivers of liking with respect to
graininess.
[0062] FIG. 2 illustrates a multivariate analysis of the control,
liquid DKP and liquid KOH samples using a principal component
analysis ("PCA") bi-plot of significantly different quantitative
descriptive analysis ("QDA") attributes. This multivariate analysis
shows groupings or clusters of the three samples based on the
quantitative measurements of Tables 5-18. By applying PCA to
descriptive analysis data, the set of dependent variables (i.e.,
attributes) is reduced to a smaller set of underlying variables
(called factors) based on patterns of correlation among the
original variables. See Sensory Evaluation of Dairy Products,
Innovations In Dairy (October 2005), which is incorporated by
reference for any useful purpose.
[0063] According to FIG. 2, both sets of liquid formula (liquid DKP
and liquid KOH) appear to have less variability in sensory
attributes than the dry DKP (control) formula. The liquid KOH
formula appears to have less variability than the liquid DKP
formula. The liquid KOH formula appears to be more closely
correlated with the positive sensory attributes of buttery, dairy
sweet, and salty than the liquid DKP and dry DKP (control)
formulas.
[0064] In addition, the liquid KOH product was preferred to the
liquid DKP utilizing a 50% potassium phosphate liquid source and
over the control dry DKP version of potassium phosphate referenced.
This would indicate that the liquid KOH product is preferred over a
potassium phosphate ingredient, whether in dry or liquid-based
form.
[0065] Although the present disclosure provides references to
specific embodiments, persons skilled in the art will recognize
that changes may be made in form and detail without departing from
the spirit and scope of the invention.
* * * * *